Light-weight bed panel and foldable bed having same

ABSTRACT

A bed includes a bed frame and a bed panel disposed on the bed frame. The bed frame includes first and second frame units disposed side by side and pivotally connected with each other. The bed panel includes a first panel unit fixedly disposed at an upper side of the first frame unit, and a second panel unit fixedly disposed at an upper side of the second bed frame unit. Each of the first and second panel units includes one or more panel assemblies. Each panel assembly in the one or more panel assemblies includes a substrate, a sponge layer and a cover. The substrate is disposed at the upper side of the first or second frame unit. The sponge layer is disposed at an upper side of the substrate, and the cover layer is disposed at an upper side of the sponge layer.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority to Chinese Utility Model Application CN 201822216532.5 filed Dec. 27, 2018. The disclosure of the application is incorporated herein for all purposes by reference in its entirety.

FIELD OF THE INVENTION

The present invention generally relates to bed panels, bed frames and beds, and more particularly, to light-weight bed panels, foldable bed frames, and beds having such light-weight bed panels and foldable bed frames.

BACKGROUND

Existing foldable beds have several advantages. For instance, they are usually simple and convenient to use. However, they have some shortcomings. For example, bed panels of most existing foldable beds are made of wood. As such, existing foldable beds are usually heavy, making them inconvenient to carry and use.

Given the current state of the art, there remains a need for bed panels and foldable beds that address the abovementioned issues.

The information disclosed in this Background section is provided for an understanding of the general background of the invention and is not an acknowledgement or suggestion that this information forms part of the prior art already known to a person skilled in the art.

SUMMARY OF THE INVENTION

The present invention provides light-weight bed panels, foldable bed frames, and beds having such light-weight bed panels and foldable bed frames.

In various exemplary embodiments, the present invention provides a bed including a bed frame, a plastic substrate, a sponge layer and a cover layer. The plastic substrate is disposed at an upper side of the bed frame, and is hollow. The sponge layer is disposed at an upper side of the plastic substrate. The cover layer is disposed at an upper side of the sponge layer.

In some exemplary embodiments, an upper surface of the plastic substrate is recessed to form an indentation, wherein the sponge layer is disposed in the indentation.

In some exemplary embodiments, at least one edge of the plastic substrate includes a first protrusion and a second protrusion, wherein a slot is formed between the first and second protrusions and configured to connect the plastic substrate with the bed frame.

In an exemplary embodiment, a locking member is disposed in the slot and configured to fixedly connect the plastic substrate with the bed frame.

In some exemplary embodiments, the bed frame includes a first frame unit and a second frame unit pivotally connected with each other.

In an exemplary embodiment, the first and second frame units are pivotally connected with each other by a first connecting member. The first frame unit is pivotally connected with a first end of the first connecting member and rotatable with respect to the first connecting member along first pivotal axis. The second frame unit is pivotally connected with the first connecting member at a second end of the first connecting member and rotatable with respect to the first connecting member along a second pivotal axis.

In another exemplary embodiment, the first and second frame units are pivotally connected with each other by a second connecting member and a third connecting member. The first frame unit is fixedly connected with the second connecting member; the second frame unit is fixedly connected with the third connecting member; and the second and third pieces are pivotally connected with each other at a third pivotal axis.

In still another exemplary embodiment, the first and second frame units are pivotally connected with each other by fourth, fifth, and sixth connecting members. Each of the fourth and fifth connecting members includes a first segment and a second segment. The first frame unit is pivotally connected with the first segment of the fourth connecting member, and rotatable with respect to the first segment of the fourth connecting member along a fourth pivotal axis. The second frame unit is pivotally connected with the first segment of the fifth connecting member, and rotatable with respect to the first segment of the fifth connecting member along a fifth pivotal axis. The second segment of the fourth connecting member and the second segment of the fifth connecting member are pivotally connected with each other, and rotatable with respect to each other along a sixth pivotal axis. In some exemplary embodiments, the first and second segments of the fourth or fifth connecting member are formed or welded together.

In various exemplary embodiments, the present invention provides a bed panel for use with a bed frame. The bed panel includes first and second panel units. The first panel unit is configured to be fixedly disposed at an upper side of a first frame unit of the bed frame, and the second panel unit is configured to be fixedly disposed at an upper side of a second bed frame unit. Each of the first and second panel units includes one or more panel assemblies. Each panel assembly in the one or more panel assemblies includes a substrate disposed at the upper side of the first or second frame unit, a sponge layer disposed at an upper side of the substrate, and a cover layer disposed at an upper side of the sponge layer.

In some exemplary embodiments, the substrate is made of a material including plastics.

In some exemplary embodiments, the substrate is formed with a cavity.

In some exemplary embodiments, the one or more panel assemblies includes two, three or more panel assemblies, and adjacent assemblies are connected with each other.

In some exemplary embodiments, an upper surface of the substrate is recessed to form an indentation, wherein the sponge layer is disposed in the indentation.

In some exemplary embodiments, at least one edge of the bed panel includes a first protrusion and a second protrusion, wherein a slot is formed between the first and second protrusions and configured to connect the bed panel with the bed frame.

In an exemplary embodiment, a locking member is disposed in the slot and configured to fixedly connect the bed panel with the bed frame.

In various exemplary embodiments, the present invention provides a bed including a bed panel disclosed herein and a bed frame. The bed frame includes first and second frame units disposed side by side and pivotally connected with each other at adjacent ends. The bed panel is disposed on the bed frame.

In an exemplary embodiment, the first and second frame units are pivotally connected with each other by a first connecting member, wherein the first frame unit is pivotally connected with a first end of the first connecting member and rotatable with respect to the first connecting member along first pivotal axis; and the second frame unit is pivotally connected with the first connecting member at a second end of the first connecting member and rotatable with respect to the first connecting member along a second pivotal axis.

In another exemplary embodiment, the first and second frame units are pivotally connected with each other by a second connecting member and a third connecting member, wherein the first frame unit is fixedly connected with the second connecting member; the second frame unit is fixedly connected with the third connecting member; and the second and third connecting members are pivotally connected with each other at a third pivotal axis.

In still another exemplary embodiment, the first and second frame units are pivotally connected with each other by fourth and fifth connecting members, wherein each of the fourth and fifth connecting members includes a first segment and a second segment; the first frame unit is pivotally connected with the first segment of the fourth connecting member, and rotatable with respect to the first segment of the fourth connecting member along a fourth pivotal axis; the second frame unit is pivotally connected with the first segment of the fifth connecting member, and rotatable with respect to the first segment of the fifth connecting member along a fifth pivotal axis; and the second segment of the fourth connecting member and the second segment of the fifth connecting member are pivotally connected with each other, and rotatable with respect to each other along a sixth pivotal axis. In some exemplary embodiments, the first and second segments of the fourth or fifth connecting member are formed or welded together.

The bed panels, bed frames, and beds of the present invention have other features and advantages that will be apparent from, or are set forth in more detail in, the accompanying drawings, which are incorporated herein, and the following Detailed Description, which together serve to explain certain principles of exemplary embodiments of the present invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated into and constitute a part of this specification, illustrate one or more exemplary embodiments of the present invention and, together with the Detailed Description, serve to explain the principles and implementations of exemplary embodiments of the invention.

FIG. 1 is a perspective view illustrating an exemplary foldable bed in an unfolded state in accordance with exemplary embodiments of the present invention.

FIG. 2 is a partially disassembled side view illustrating an exemplary foldable bed in an unfolded state in accordance with exemplary embodiments of the present invention.

FIG. 3 is a cross-sectional view illustrating a component of an exemplary foldable bed in accordance with exemplary embodiments of the present invention.

FIG. 4 is a schematic view illustrating a cross-section taking along line A of FIG. 1.

FIG. 5 is a perspective view illustrating an exemplary foldable bed in an intermediate state in accordance with exemplary embodiments of the present invention.

FIG. 6 is a side view illustrating the exemplary foldable bed of FIG. 5.

FIG. 7 is a perspective view illustrating an exemplary foldable bed in an intermediate state in accordance with exemplary embodiments of the present invention.

FIG. 8 is a side view illustrating the exemplary foldable bed of FIG. 7.

FIG. 9 is a side view illustrating an exemplary foldable bed in an intermediate state in accordance with exemplary embodiments of the present invention.

FIG. 10 is a side view illustrating the exemplary foldable bed of FIG. 9 in a folded state in accordance with exemplary embodiments of the present invention.

As will be apparent to those of skill in the art, the components illustrated in the figures described above are combinable in any useful number and combination. The figures are intended to be illustrative in nature and are not limiting.

DETAILED DESCRIPTION

Reference will now be made in detail to implementations of exemplary embodiments of the present invention as illustrated in the accompanying drawings. The same reference indicators will be used throughout the drawings and the following detailed description to refer to the same or like parts. Those of ordinary skill in the art will understand that the following detailed description is illustrative only and is not intended to be in any way limiting. Other embodiments of the present invention will readily suggest themselves to such skilled persons having benefit of this disclosure.

In the interest of clarity, not all of the routine features of the implementations described herein are shown and described. It will be appreciated that, in the development of any such actual implementation, numerous implementation-specific decisions are made in order to achieve the developer's specific goals, such as compliance with application- and business-related constraints, and that these specific goals will vary from one implementation to another and from one developer to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking of engineering for those of ordinary skill in the art having the benefit of this disclosure.

Many modifications and variations of the exemplary embodiments set forth in this disclosure can be made without departing from the spirit and scope of the embodiments, as will be apparent to those skilled in the art. The specific exemplary embodiments described herein are offered by way of example only, and the disclosure is to be limited only by the terms of the appended claims, along with the full scope of equivalents to which such claims are entitled.

Embodiments of the present invention are described in the context of light-weight bed panels, foldable bed frames, and beds having such light-weight bed panels and foldable bed frames. The beds of the present invention can be of various sizes including but not limited to twin, full, queen and king sizes, and of various shapes including but not limited to rectangles and squares. The bed frames can be made of various materials including but not limited to metals (e.g., cast iron, steel, aluminum), plastics and woods. The bed panels of the present invention are light-weight.

In general, a foldable bed of the present invention includes a bed frame and a bed panel disposed on the bed frame. The bed frame includes two or more frame units pivotally connected with each other at their adjacent ends, resulting in a foldable bed frame. The bed panel usually includes two or more panel units. In some exemplary embodiments, corresponding to each frame unit in the two or more frame units, the bed panel includes a panel unit fixedly disposed at an upper side of the frame unit. A panel unit can include one or more panel assemblies. In some exemplary embodiments, a bed panel, a panel unit or a panel assembly is of a multi-layer structure including a plastic hollow substrate, a sponge layer and/or a cover.

By way of example, FIGS. 1 and 2 illustrate a bed including a bed frame such as bed frame 2 and a bed panel such as bed panel 8 disposed on the bed frame. Bed frame 2 includes first frame unit 21 and second frame unit 22 disposed side by side and pivotally connected with each other at their adjacent ends. Corresponding to the first and second frame units, bed panel 8 includes first panel unit 81 and second panel unit 82. The first panel unit is fixedly disposed at an upper side of the first frame unit, and the second panel unit is fixedly disposed at an upper side of the second bed frame unit.

In some exemplary embodiments, each of the first and second panel units includes one or more panel assemblies. For instance, by way of example, FIGS. 1 and 2 illustrate first panel unit 81 including two panel assemblies, i.e., 81 a and 81 b, and second panel unit 82 including three panel assemblies, i.e., 82 a, 82 b and 82 c. In some exemplary embodiments, adjacent panel assemblies within the same panel unit are connected with each other.

Panel assemblies in the same panel unit or in different panel units can have the same or different configurations (e.g., in terms of size, shape, material, structure, or the like). By way of example, FIGS. 1 and 2 illustrate the panel assemblies having different sizes but with the same layer structure, e.g., each panel assembly including a substrate such as substrate 3, a first layer such as sponge layer 4 and a second layer such as cover layer 5.

Substrate 3 is disposed at the upper side of the first or second frame unit. Sponge layer 4 is disposed at an upper side, e.g., upper surface 32 of the substrate, and cover layer 5 is disposed at an upper side of the sponge layer to cover the sponge layer. In an exemplary embodiment, sponge layer 4 and cover layer 5 are glued together, for instance, by spraying an adhesive on the sponge layer or the cover layer or both. The bonded sponge and cover layers are then glued to the upper surface of the substrate, for instance, by spraying an adhesive on the back surface of the sponge layer or the upper surface of the substrate or both. In another exemplary embodiment, sponge layer 4 is glued to the upper surface of the substrate and then the cover layer is glued to the sponge layer.

Referring to FIG. 3, in some exemplary embodiments, upper surface 32 of substrate 3 is recessed to form an indentation such as indentation 32 a. In such embodiments, the sponge layer is disposed in the indentation. In an exemplary embodiment, the indentation is configured such that when the sponge layer is disposed in the indentation, the sponge layer is flush with the edge of the indentation or below the edge of the indentation. Configuration with an indentation reduces the weight of the bed panel and improves the aesthetics and portability of the bed panel.

In some exemplary embodiments, substrate 3 is made of a light-weight material such as a plastic to reduce the weight of the bed panel. In some exemplary embodiments, substrate 3 is hollow, e.g., formed with a cavity such as cavity 31. This further reduces the weight of the bed panel.

The cover layer can be made of any suitable material including but not limited to fabric, coating, leather or the like. In some exemplary embodiments, the cover layer is made of a material comparing leather (either genuine or man-made). The cover layer protects the sponge layer, and improves aesthetics and portability of the bed panel.

In some exemplary embodiments, at least one edge of bed panel 81 includes a first protrusion and a second protrusion, and a slot is formed between the first and second protrusions to connect the bed panel with the bed frame. For instance, by way of example, FIGS. 1 and 4 illustrate substrate 3 of panel assembly 81 a formed with first protrusion 33 and second protrusion 34. Slot 35 is formed between the first and second protrusions and configured to connect (e.g., by snap-fitting, press-fitting, or the like) with the bed frame (e.g., a peripheral bar of the bed frame). In some exemplary embodiments, a locking member such as locking member 2 a is disposed in the slot and configured to fixedly connect the bed panel with the bed frame. The locking member helps to fix the bed panel on the bed frame and prevent displacement of the bed panel.

In various exemplary embodiments, first frame unit 21 and second frame unit 22 are pivotally connected with each other by a plurality of connectors. For instance, in some exemplary embodiments, the first and second frame units are pivotally connected with each other by two connectors, one disposed at a left side and one disposed at a right side of the bed frame. In some exemplary embodiments, a connector includes one or more connecting members.

For instance, by way of example, FIGS. 5 and 6 illustrate the first and second frame units are pivotally connected with each other by one or more connectors 6. In some exemplary embodiments, connector 6 includes one connecting member such as first connecting member 61. The first frame unit is pivotally connected with the first connecting member at the first end of the first connecting member and rotatable with respect to the first connecting member along first pivotal axis 61 a (e.g., shaft, hinge, bolt or the like). Similarly, the second frame unit is pivotally connected with the first connecting member at the second end of the first connecting member and rotatable with respect to the first connecting member along second pivotal axis 61 b. In some exemplary embodiments, first connecting member 61 includes a limiting member such as limiting member 63 disposed or formed at the lower portion of the first connecting member. When the bed frame is unfolded or in use, limiting member 63 helps to stabilize the bed frame and reduce sway or vibration.

It should be noted that the first or second end of a connecting member as used herein refers to an end of the connecting member or a portion that includes an end of the connecting member. For instance, in the exemplary embodiment illustrated in FIG. 6, the first end of first connecting member 61 refers to the left portion of first connecting member 61 and the second end of first connecting member 61 refers to the right portion of first connecting member 61 in FIG. 6.

As another example, FIGS. 7 and 8 illustrate the first and second frame units are pivotally connected with each other by one or more connectors 6′. In some exemplary embodiments, connector 6′ includes two connecting members such as second connecting member 61′ and third connecting member 62′. In some exemplary embodiments, the second or third connecting member includes two symmetrically disposed pieces. The first frame unit is fixedly connected with the second connecting member, for instance by welding or the like. The second frame unit is fixedly connected with the third connecting member. The second and third connecting members are pivotally connected with each other and rotatable with respect to each other along third pivotal axis 63′. As such, first frame unit 21 and second frame unit 22 are foldable along the third pivotal axis.

As a further example, FIGS. 9 and 10 illustrate the first and second frame units are pivotally connected with each other by one or more connectors 6″. In some exemplary embodiments, connector 6″ includes two connecting members such as fourth connecting member 61″ and fifth connecting member 62″. Each of the fourth and fifth connecting members includes a first segment and a second segment. For instance, fourth connecting member 61″ includes first segment 61 a″ and second segment 61 b″, and fifth connecting member 62″ includes first segment 62 a″ and second segment 62 b″. In some exemplary embodiments, the first and second segments of the fourth or fifth connecting member are formed or welded together.

In some exemplary embodiments, the first frame unit is pivotally connected with the first segment of the fourth connecting member, and rotatable with respect to the first segment of the fourth connecting member along fourth pivotal axis 63″. The second frame unit is pivotally connected with the first segment of the fifth connecting member, and rotatable with respect to the first segment of the fifth connecting member along fifth pivotal axis 62 c″. The second segment of the fourth connecting member and the second segment of the fifth connecting member are pivotally connected with each other, and rotatable with respect to each other along sixth pivotal axis 66″. Such connections make the folding and unfolding of the bed frame smoother and more stable.

The terminology used herein is for the purpose of describing particular implementations only and is not intended to be limiting of the claims. As used in the description of the implementations and the appended claims, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be understood that the terms “lower” or “upper”, and etc. are used to describe features of the exemplary embodiments with reference to the positions of such features as displayed in the figures. It will be understood that, although the terms “first,” “second,” etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first frame unit could be termed a second frame unit, and, similarly, a second frame unit could be termed a first frame, without changing the meaning of the description, so long as all occurrences of the “first frame unit” are renamed consistently and all occurrences of the “second frame unit” are renamed consistently. 

What is claimed is:
 1. A bed comprising: a bed frame; a plastic substrate disposed at an upper side of the bed frame, wherein the plastic substrate is hollow; a sponge layer disposed at an upper side of the plastic substrate; and a cover layer disposed at an upper side of the sponge layer.
 2. The bed of claim 1, wherein an upper surface of the plastic substrate is recessed to form an indentation, wherein the sponge layer is disposed in the indentation.
 3. The bed of claim 1, wherein at least one edge of the plastic substrate comprises a first protrusion and a second protrusion, wherein a slot is formed between the first and second protrusions and configured to connect the plastic substrate with the bed frame.
 4. The bed of claim 3, wherein a locking member is disposed in the slot and configured to fixedly connect the plastic substrate with the bed frame.
 5. The bed of claim 1, wherein the bed frame comprises a first frame unit and a second frame unit pivotally connected with each other.
 6. The bed of claim 5, wherein the first and second frame units are pivotally connected with each other by a first connecting member, wherein the first frame unit is pivotally connected with a first end of the first connecting member and rotatable with respect to the first connecting member along first pivotal axis; and the second frame unit is pivotally connected with the first connecting member at a second end of the first connecting member and rotatable with respect to the first connecting member along a second pivotal axis.
 7. The bed of claim 5, wherein the first and second frame units are pivotally connected with each other by a second connecting member and a third connecting member, wherein the first frame unit is fixedly connected with the second connecting member; the second frame unit is fixedly connected with the third connecting member; and the second and third pieces are pivotally connected with each other at a third pivotal axis.
 8. The bed of claim 5, wherein the first and second frame units are pivotally connected with each other by fourth, fifth, and sixth connecting members, wherein each of the fourth and fifth connecting members comprises a first segment and a second segment; the first frame unit is pivotally connected with the first segment of the fourth connecting member, and rotatable with respect to the first segment of the fourth connecting member along a fourth pivotal axis; the second frame unit is pivotally connected with the first segment of the fifth connecting member, and rotatable with respect to the first segment of the fifth connecting member along a fifth pivotal axis; and the second segment of the fourth connecting member and the second segment of the fifth connecting member are pivotally connected with each other, and rotatable with respect to each other along a sixth pivotal axis.
 9. A bed panel for use with a bed frame, the bed panel comprising: a first panel unit to be fixedly disposed at an upper side of a first frame unit of the bed frame; and a second panel unit to be fixedly disposed at an upper side of a second bed frame unit, wherein: each of the first and second panel units comprises one or more panel assemblies; and each panel assembly in the one or more panel assemblies comprises a substrate disposed at the upper side of the first or second frame unit, a sponge layer disposed at an upper side of the substrate, and a cover layer disposed at an upper side of the sponge layer to cover the sponge layer.
 10. The bed of claim 9, wherein the substrate is made of a material comprising plastics.
 11. The bed of claim 9, wherein the substrate is formed with a cavity.
 12. The bed of claim 9, wherein the one or more panel assemblies comprises two, three or more panel assemblies, wherein adjacent panel assemblies are connected with each other.
 13. The bed of claim 9, wherein an upper surface of the substrate is recessed to form an indentation, wherein the sponge layer is disposed in the indentation.
 14. The bed of claim 9, wherein at least one edge of the bed panel comprises a first protrusion and a second protrusion, wherein a slot is formed between the first and second protrusions and configured to connect the bed panel with the bed frame.
 15. The bed of claim 9, wherein a locking member is disposed in the slot and configured to fixedly connect the bed panel with the bed frame.
 16. A bed comprising: the bed panel of claim 9; and the bed frame comprising the first frame unit and the second frame unit, wherein: the first frame unit and the second frame unit of the bed frame are disposed side by side and pivotally connected with each other at adjacent ends thereof; and the bed panel is disposed on the bed frame.
 17. The bed of claim 16, wherein the first and second frame units are pivotally connected with each other by a first connecting member, wherein the first frame unit is pivotally connected with a first end of the first connecting member and rotatable with respect to the first connecting member along first pivotal axis; and the second frame unit is pivotally connected with the first connecting member at a second end of the first connecting member and rotatable with respect to the first connecting member along a second pivotal axis.
 18. The bed of claim 16, wherein the first and second frame units are pivotally connected with each other by a second connecting member and a third connecting member, wherein the first frame unit is fixedly connected with the second connecting member; the second frame unit is fixedly connected with the third connecting member; and the second and third connecting members are pivotally connected with each other at a third pivotal axis.
 19. The bed of claim 16, wherein the first and second frame units are pivotally connected with each other by fourth and fifth connecting members, wherein each of the fourth and fifth connecting members comprises a first segment and a second segment; the first frame unit is pivotally connected with the first segment of the fourth connecting member, and rotatable with respect to the first segment of the fourth connecting member along a fourth pivotal axis; the second frame unit is pivotally connected with the first segment of the fifth connecting member, and rotatable with respect to the first segment of the fifth connecting member along a fifth pivotal axis; and the second segment of the fourth connecting member and the second segment of the fifth connecting member are pivotally connected with each other, and rotatable with respect to each other along a sixth pivotal axis.
 20. The bed of claim 19, wherein the first and second segments of the fourth or fifth connecting member are formed or welded together. 